Door and frame adjustment tool

ABSTRACT

A tool includes a hammered shaping device having a first working surface and a thickness measured in a direction perpendicular to said first working surface. The first working surface has a length and a width. The length is about equal to a length of a hinge leaf. The width is about equal to a width of the hinge leaf. The thickness is at least two times a thickness of the hinge leaf. The hammered shaping device is fabricated of a material that can be hammered without substantial permanent deformation. The hammered shaping device can have a gauge. The hammered shaping device can have countersunk holes to facilitate connection to a door or door frame hinge reinforcement plate.

RELATED APPLICATION AND PRIORITY

This application claims priority of Provisional U.S. Patent Application 60/663,856, filed Mar. 21, 2005, incorporated herein by reference.

FIELD

This patent application generally relates to door and door frame alignment. More particularly, it relates to a system for aligning a door and a door frame. Even more particularly, it relates to a system for precisely measuring misalignment and for facilitating hammering or wrenching to obtain alignment within a close tolerance.

BACKGROUND

Hinge reinforcements located on doors and door frames frequently get bent outwardly when the door is opened too forcefully, when the door is opened too far, or when the door is whipped by the wind. A hinge reinforcement that is bent too much can cause the door to be misaligned with the frame, preventing the door from closing or latching. The door may be so far out of alignment that it hits the frame which can cause damage to both the door and the frame. If the door fails to latch a security risk is posed. Thus, it is important to return the hinge reinforcement to its original shape and location so that the door is properly aligned in the frame and the door closes and latches properly.

Typically, doors and door frames have been bent outwardly as the door hinge pulls on the door on one side and on the door frame on the other side. Hammering has been the technique for restoring alignment of both door and door frame. However, there has been no way other than crudely by eye of knowing exactly where to hammer and how much to hammer. An instrument to measure how much the frame or door is out of alignment and where the misalignment is located has long been needed. A device for mor precisely locating where the hammer blows fall has also long been needed. A device and system for both measuring and facilitating hammering and wrenching are provided in the present patent application. In addition, a better alignment kit has been needed to provide all the parts needed for fully aligning a door and door frame, and this alignment kit is also provided by this patent application.

SUMMARY

One aspect of the present patent application is a tool that includes a hammered shaping device having a first working surface and a thickness measured in a direction perpendicular to said first working surface. The first working surface has a length and a width. The length is about equal to a length of a hinge leaf. The width is about equal to a width of the hinge leaf. The thickness is at least two times a thickness of the hinge leaf. The hammered shaping device is fabricated of a material that can be hammered without substantial permanent deformation.

Another aspect of the present patent application is a tool, comprising a hammered shaping device having a gauge.

Another aspect of the present patent application is a tool, comprising a hammered shaping device having a plurality of countersunk holes for attaching the hammered shaping device to a workpiece.

Another aspect of the present patent application is a method of using a tool to align a hinge reinforcement, comprising providing a hammer and a hammered shaping device. The hammered shaping device includes a gauge. The hammered shaping device is inserted into a hinge recess, wherein the hinge recess includes the hinge reinforcement and a hinge periphery. A location where the hinge reinforcement extends out of alignment as indicated by location of the gauge with respect to the hinge periphery is observed. The hammered shaping device is hammered in locations indicated by the location to align the hinge reinforcement.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing will be apparent from the following detailed description as illustrated in the accompanying drawings, in which:

FIG. 1 a is a three dimensional view of one embodiment;

FIGS. 2 a-2 c provide front, top and side views of the embodiment of FIG. 1 a;

FIGS. 3 a and 3 d are three dimensional views of a standard frame with a frame hinge reinforcement plate welded in;

FIGS. 3 b and 3 e are three dimensional views of a standard door with a frame hinge reinforcement plate welded in;

FIG. 3 c is a three dimensional view of a frame hinge reinforcement plate;

FIG. 4 is a three dimensional view of another embodiment;

FIG. 5 a is a cross sectional view of an embodiment of a hammered shaping device in use to fix a misaligned door or frame hinge reinforcement plate in which the hammered shaping device is hammered to push in the hinge reinforcement plate;

FIG. 5 a is a cross sectional view of another embodiment of a hammered shaping device in use to fix a misaligned door or frame hinge reinforcement plate in which hex head bolts are tightened to pull out the hinge reinforcement plate;

FIG. 6 a is a top view of a case for holding parts for a door and frame alignment kit;

FIG. 6 b is a cross sectional view of the case of FIG. 6 a;

FIG. 6 c is a top view of components that would fit into the compartments of the case of FIGS. 6 a, 6 b; and

FIG. 7 a is a top view of a larger case for holding more parts for a door and frame alignment kit;

FIG. 7 b is a cross sectional view of the case of FIG. 7 a;

DETAILED DESCRIPTION

The present application provides an adjustment tool that serves as both a gauge and as a striker or hammered shaping device. The striker or hammered shaping device can be used between the hammer and the surface being hammered. It can also be used for wrenching out a surface that was hammered in or otherwise bent in too far.

One use for the adjustment tool described in this application is to provide a device for use in hammering an object, such as a door reinforcement plate or a hinge reinforcement plate. Such a hammered shaping device is a device for use between a hammer and a surface that transmits hammer blows from the hammer to the surface.

The hammered shaping devise may have one, two, or three pairs of working surfaces. A first working surface of the hammered shaping device is a surface that can receive hammer blows from a hammer. A second working surface of the hammered shaping device is a surface opposite the first surface that can transmit the hammer blow to the object. The first working surface and the second working surface constitute a first pair of working surfaces. If the hammered shaping device is a rectangular solid it has three pairs of working surfaces that may have different dimensions, all of which can be used.

One embodiment of the hammered shaping device described in this application has several different working surfaces with different sizes allowing it to shape the entire hinge reinforcement at once or to shape only specific portions of the hinge reinforcement while leaving other portions alone. One embodiment of the hammered shaping device has a built in gauge that provides indication of the amount of shaping needed to move the hinge reinforcement into proper position. One embodiment has two, three, or four built in gauges, allowing it to be used to shape reinforcement plates in doors or door frames that have different thickness hinges. One embodiment has countersunk holes to firmly attach the hammered shaping device to the door or frame reinforcement plate to facilitate hammering in or to facilitate pulling out with threaded bolts.

In one embodiment, hammered shaping device 20 has two different sizes of rectangular hardened steel, such as cold rolled steel bars, one continuously welded on the other, as shown in FIG. 1. Two dimensions of larger bar 22 are about equal to those of a standard leaf hinge plate so larger bar fits into the space of a standard leaf hinge plate on a door or on a door frame. Dimensions of larger bar 22 typically include a length of about 4 7/16 inches, a width of about 1 ½ inches to about equal these dimensions of commonly used leaf hinge plates. Larger bar 22 can have a thickness of about 1 ½ inches. Dimensions of smaller bar 24 are typically set to about equal those of another size of hinge plate. Dimensions of smaller bar 24 are typically set to a length of about 3 15/16 and a width of about 1 ½. Thickness of smaller bar 24 may be set to about 1 inch. Bar 22 may be welded to bar 24. Smaller or larger dimensions can be used for thickness of each bar so the hammered shaping device has enough mass to transmit energy and to avoid being deformed during hammering and so it extends far enough to avoid damage to adjacent portions of a door or frame during hammering. Smaller or larger dimensions of length and width can be used to match other size hinges or for shaping other objects. An adhesive can be used between bars 22, 24 instead of a weld. Hammered shaping device 20 can also be fabricated of a single piece of hardened machined material. Alternatively it can be fabricated of a single piece of cast steel using a mold. It can also be fabricated of a material other than steel that can transfer the force of hammering.

In one embodiment gauge lines 26 a, 26 b are scribed or cut into from one to four of the sides of hammered shaping device 20 with a saw. Gauge line 26 a may be located about ⅛ inch from working surface 28, as shown in FIG. 2. Gauge line 26 b may be located about 3/16 inch from working surface 28. Which gauge line 26 a, 26 b is used depends on the thickness of hinge (not shown) used in door frame 30 or door 30′. Additional gauge lines can be provided to match thickness of other hinges that can be used. For example, three, four or any other number of gauge lines can be provided to, match thickness of various hinges.

In use, bottom working surface 28 of hammered shaping device 20 may be applied to frame hinge reinforcement plate 32 within recess 36 in frame 30, as shown in FIG. 3 a. Bottom working surface 28 of hammered shaping device 20 may also be applied to door hinge reinforcement plate 32′ within recess 36′ in door 30′, as shown in FIG. 3 b. Bottom working surface 28 has dimensions, as shown in FIGS. 1 and 2 b, which are about equal to the dimensions of about 90% of door and frame hinge reinforcement plates currently in use. Frame hinge reinforcement plate 32 separated from door or frame is shown FIG. 3 c and welded in to frame 30 or door 30′ in FIGS. 3 d, 3 e.

One can strike working surface 38 of hammered shaping device 20 with a hammer to direct hammering force through hammered shaping device 20 and through working surface 28 onto various portions of reinforcement plate 32, 32′. The locations on top working surface 38 selected for hammering can be determined using gauge 26 a, 26 b, as shown in FIG. 5 a, which shows an example requiring hammering along portion 39. One can also apply top working surface 38 to reinforcement plate 32, 32′ and hammer on bottom working surface 28 to direct hammering through hammered shaping device 20 and through working surface 38 more on one end of reinforcement plate 32, 32′ than the other. Working surface 38 has a length dimension that is smaller than the length dimension of working surface 28.

One can also hammer on end working surface 40 or end working surface 42 to concentrate force in a particular smaller area of reinforcement plate 32, 32′. Working surfaces 40 and 42 have the same dimensions as each other. They also have the same width as working surfaces 28 and 38. But working surfaces 40 and 42 have length dimensions that differ from those of working surfaces 28 and 38. As shown in FIG. 1 hammered shaping device 20 has three differently dimensioned pairs of working surfaces that can be placed in contact with reinforcement plate 32, 32′. And one of the pairs, 28, 38, have working surfaces with one dimension equal and one dimension slightly different. Although not shown, gauge lines can also be provided adjacent working surfaces 38, 40, and 42.

Another embodiment provides hammered shaping device 50 has a single size of rectangular hardened steel fabricated of a single bar of hardened steel with a uniform rectangular solid shape, as shown in FIG. 4. In this embodiment hammered shaping device 50 has three pairs of equally dimensioned opposed working surfaces 28′-38′, 40′-42′, and 52-54.

Countersunk holes 56 aligned and threaded holes 58, 58′ in frame and door hinge reinforcement plates 32, 32′ can be used along with threaded bolts with washers and large heads (not shown) to wrench out portions of door hinge reinforcement plates 32, 32′ that bent in or were hammered in too much, as shown in FIG. 5 b.

Alternatively, countersunk holes 56 aligned with threaded holes 58, 58′ in frame and door hinge reinforcement plates 32, 32′ can be used along with threaded bolts 60 having heads 62 that fit into the countersink of countersunk holes 56 to hold hammered shaping device 20, 50 tightly to door hinge reinforcement plates 32, 32′ to facilitate hammering without vibration and without having to hold hammered shaping device 50 by hand. Control over realignment is also greatly facilitated by having hammered shaping device 20, 50 connected to frame or door reinforcement plate 32, 32′.

Hammered shaping device 20, 50 may be included in kit 70 that includes box 72, as shown in FIGS. 6 a, 6 b foam 74, cutouts 76 in foam 74, and other components and devices useful in realigning a door or a door frame, as shown in FIG. 6 c. These components and devices include hinge shims, 82, hammer 84, metal and wood hinge screws 86, left and right hand reinforcing pivots 88, kick plate screws 90, weatherstrip screws 92, through bolts 96, screw driver 98, bits 100 for screw driver 98, drill attachment 102 for bits 100, triflow lubricant 104, and hex wrench set 106 and other screws and fasteners 108, 110. Larger box 72′, as shown in FIG. 7 a, 7 b can be used for holding additional components and devices. Box 72′ also has foam 74′ with cutouts 76′, for the various components and devices.

While the disclosed methods and systems have been shown and described in connection with illustrated embodiments, various changes may be made therein without departing from the spirit and scope of the invention as defined in the appended claims. 

1. A tool, comprising hammered shaping device having a first working surface and a thickness measured in a direction perpendicular to said first working surface, wherein said first working surface has a length and a width, said length about equal to a length of a hinge leaf, said width about equal to a width of the hinge leaf, said thickness at least two times a thickness of the hinge leaf, wherein said hammered shaping device is fabricated of a material that can be hammered without substantial permanent deformation.
 2. A tool, as recited in claim 1, wherein said thickness is at least five times a thickness of the hinge leaf.
 3. A tool, as recited in claim 1, wherein said thickness is at least ten times a thickness of the hinge leaf.
 4. A tool, as recited in claim 1, further comprising a second working surface opposite said first working surface, wherein said second working surface has a dimension less than a corresponding dimension of said first working surface.
 5. A tool, as recited in claim 4, wherein said dimension is less by at least ½ inch.
 6. A tool, as recited in claim 4, further comprising a third working surface orthogonal to said first working surface, wherein said third working surface has a dimension extending perpendicular to said first working surface, wherein said dimension is less than said thickness.
 7. A tool, as recited in claim 1, further comprising a gauge located adjacent said first working surface, wherein said gauge is located at a distance from said first working surface about equal to a thickness of a first hinge leaf.
 8. A tool, as recited in claim 7, wherein said hammered shaping device is for aligning a door or door frame hinge reinforcement plate having a hinge recess, wherein said hinge recess includes a hinge recess periphery, wherein said gauge is located to measure depth of said hinge recess.
 9. A tool, as recited in claim 7, further comprising a second gauge located adjacent said first working surface, wherein said second gauge is located at a distance from said first working surface about equal to a thickness of a second hinge leaf having a thickness different from said first hinge leaf.
 10. A tool, as recited in claim 1, further comprising countersunk holes for attaching said hammered shaping device to threaded holes of a hinge reinforcement plate.
 11. A tool, comprising a hammered shaping device having a gauge.
 12. A tool, as recited in claim 11, further comprising a second gauge.
 13. A tool, comprising a hammered shaping device having a plurality of countersunk holes for attaching said hammered shaping device to a workpiece.
 14. A tool, as recited in claim 13, wherein said hammered shaping device has a first working surface and a thickness measured in a direction perpendicular to said first working surface, wherein said thickness is at least five times a thickness of a hinge leaf.
 15. A tool, as recited in claim 14, wherein said thickness is at least ten times a thickness of the hinge leaf.
 16. A tool, as recited in claim 13, wherein said hammered shaping device has a first working surface and a thickness measured in a direction perpendicular to said first working surface, wherein said length is about equal to a length of a hinge leaf and said width about is about equal to a width of the hinge leaf.
 17. A tool, as recited in claim 13, wherein said hammered shaping device has a first working surface, further comprising a gauge located adjacent said first working surface, wherein said gauge is located at a distance from said first working surface about equal to a thickness of a hinge leaf.
 18. A method of using a tool to align a hinge reinforcement, comprising: a. providing a hammer and a hammered shaping device, wherein said hammered shaping device includes a gauge; b. inserting said hammered shaping device into a hinge recess, wherein said hinge recess includes the hinge reinforcement and a hinge periphery; and c. observing a location where the hinge reinforcement extends out of alignment as indicated by location of said gauge with respect to the hinge periphery; and d. hammering said hammered shaping device in locations indicated by said location to align said hinge reinforcement.
 19. A method as recited in claim 19, further comprising a first working surface, a second working surface, and a surface intersecting said first working surface, wherein said hammering is accomplished by striking said second working surface, wherein said gauge is on said surface intersecting said first working surface.
 20. A method as recited in claim 19, wherein said hammered shaping device includes a plurality of said gauges on said surface intersecting said first working surface.
 21. A method as recited in claim 19, wherein said hammered shaping device includes a gauge on said surface intersecting said first working surface that is adjacent said first working surface and a gauge on said surface intersecting said first working surface that is adjacent said second working surface.
 22. A method as recited in claim 19, further comprising connecting said hammered shaping device to said hinge recess. 